Solar module frames and installation

Abstract

A method for coupling a first solar module frame and a second solar module frame to a torque tube includes: placing a rail at the torque tube; placing a first outward extending flange of the first solar module frame at the rail; placing a second outward extending flange of the second solar module frame over the first outward extending flange at the rail; and inserting a fastener at the second outward extending flange, the first outward extending flange, and the rail.

What is claimed is: 
     
         1 . A method for coupling a first solar module frame and a second solar module frame to a torque tube, the method comprising the steps of:
 placing a rail at the torque tube;   placing a first outward extending flange of the first solar module frame at the rail;   placing a second outward extending flange of the second solar module frame over the first outward extending flange at the rail; and   inserting a fastener at the second outward extending flange, the first outward extending flange, and the rail.   
     
     
         2 . The method of  claim 1 , wherein the second outward extending flange is placed over the first outward extending flange at the rail after the first outward extending flange is placed at the rail. 
     
     
         3 . The method of  claim 2 , wherein the second outward extending flange is placed over the first outward extending flange at the rail by stacking the second outward extending flange on top of the first outward extending flange at the rail. 
     
     
         4 . The method of  claim 3 ,
 wherein the first outward extending flange is placed at the rail to directly contact the rail, and   wherein the second outward extending flange is stacked on top of the first outward extending flange at the rail such that the second outward extending flange directly contacts the first outward extending flange.   
     
     
         5 . The method of  claim 3 ,
 wherein the first outward extending flange of the first solar module frame extends horizontally outward from a first sidewall of the first solar module frame,   wherein the second outward extending flange of the second solar module frame extends horizontally outward from a second sidewall of the second solar module frame, and   wherein the second outward extending flange is stacked on top of the first outward extending flange at the rail to define a fastening gap between the first sidewall of the first solar module frame, the second sidewall of the second solar module frame, and the stacked first and second outward extending flanges.   
     
     
         6 . The method of  claim 5 , wherein the fastening gap is open at a top side that is opposite the rail. 
     
     
         7 . The method of  claim 6 , wherein inserting the fastener at the second outward extending flange, the first outward extending flange, and the rail comprises inserting the fastener through the fastening gap from the top side that is opposite the rail. 
     
     
         8 . The method of  claim 7 , wherein inserting the fastener through the fastening gap from the top side that is opposite the rail comprises inserting the fastener through the fastening gap from the top side, then through the second outward extending flange, then through the first outward extending flange, and then into the rail. 
     
     
         9 . The method of  claim 5 ,
 wherein the first solar module frame further comprises a first photovoltaic receptacle, the first photovoltaic receptacle extending horizontally outward from the first sidewall in a direction opposite the first outward extending flange and opposite the fastening gap,   wherein the second solar module frame further comprises a second photovoltaic receptacle, the second photovoltaic receptacle extending horizontally outward from the second sidewall in a direction opposite the second outward extending flange and opposite the fastening gap.   
     
     
         10 . The method of  claim 1 , further comprising:
 after placing the rail at the torque tube and before placing the first and second outward extending flanges at the rail, inserting a second fastener at the rail to couple the rail to the torque tube.   
     
     
         11 . The method of  claim 1 , wherein the fastener is inserted at the second outward extending flange, the first outward extending flange, and the rail through an open top side of a fastening gap that is defined between first solar module frame and the second solar module frame. 
     
     
         12 . The method of  claim 11 , wherein the fastening gap defines a fastening gap width, and wherein the fastening gap width is greater than a width of the fastener. 
     
     
         13 . A solar module coupling system comprising:
 a first solar module frame comprising a first sidewall, a first outward extending flange that extends out horizontally from the first sidewall, and a first photovoltaic receptacle that extends out horizontally from the first sidewall in a direction opposite the first outward extending flange;   a second solar module frame comprising a second sidewall, a second outward extending flange that extends out horizontally from the second sidewall, and a second photovoltaic receptacle that extends out horizontally from the second sidewall in a direction opposite the second outward extending flange, wherein the second outward extending flange is configured to overlay the first outward extending flange; and   a fastener configured to couple the first and second solar module frames to a rail at a torque tube, wherein, when the second outward extending flange overlays first outward extending flange, the fastener is configured to extend through the overlaid first and second outward extending flanges and into the rail at the torque tube.   
     
     
         14 . The system of  claim 13 , wherein, when the second outward extending flange overlays first outward extending flange, the first and second outward extending flanges are configured to create a fastening gap between the first sidewall of the first solar module frame, the second sidewall of the second solar module frame, and the overlaid first and second outward extending flanges. 
     
     
         15 . The system of  claim 14 , wherein the fastener is configured to be inserted through the fastening gap from a top side of the first and second solar modules frames opposite a bottom side of the first and second solar modules frames configured to interface with a torque tube. 
     
     
         16 . The system of  claim 13 ,
 wherein the first sidewall extends vertically, at a normal angle relative to the first outward extending flange, between the first outward extending flange and the first photovoltaic receptacle, and   wherein the second sidewall extends vertically, at a normal angle relative to the second outward extending flange, between the second outward extending flange and the second photovoltaic receptacle.   
     
     
         17 . The system of  claim 16 ,
 wherein the first photovoltaic receptacle is defined, at least in part, by a free-floating end of a first photovoltaic receptacle wall that extends in a direction opposite the first outward extending flange, and   wherein the second photovoltaic receptacle is defined, at least in part, by a free-floating end of a second photovoltaic receptacle wall that extends in a direction opposite the second outward extending flange.   
     
     
         18 . The system of  claim 13 , wherein the first sidewall extends vertically, at a skewed angle relative to the first
 outward extending flange, between the first outward extending flange and the first photovoltaic receptacle, and   wherein the second sidewall extends vertically, at a skewed angle relative to the second outward extending flange, between the second outward extending flange and the second photovoltaic receptacle.   
     
     
         19 . The system of  claim 18 ,
 wherein the first sidewall includes a first corrugated portion that extends vertically, at the skewed angle relative to the first outward extending flange, between the first outward extending flange and the first photovoltaic receptacle, and   wherein the second sidewall includes a second corrugated portion that extends vertically, at the skewed angle relative to the second outward extending flange, between the second outward extending flange and the second photovoltaic receptacle.   
     
     
         20 . The system of  claim 13 ,
 wherein the first solar module frame further comprises a first plurality of damping slots at the first sidewall, the first plurality of damping slots configured to permit flexing of the first sidewall, and   wherein the second solar module frame further comprises a second plurality of damping slots at the second sidewall, the second plurality of damping slots configured to permit flexing of the second sidewall.